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LEGO Simulation Overview

Lean Lego simulation created by Michael Thelen. twitter: http://twitter.com/#!/mdthelen linkedin: http://www.linkedin.com/in/michaeldthelen Find more like this at https://www.leansimulations.org/

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leansimulation8106
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5K views17 pages

LEGO Simulation Overview

Lean Lego simulation created by Michael Thelen. twitter: http://twitter.com/#!/mdthelen linkedin: http://www.linkedin.com/in/michaeldthelen Find more like this at https://www.leansimulations.org/

Uploaded by

leansimulation8106
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
  • Introduction to LEGO Simulation
  • Lean System Concepts
  • The Toyota Production System
  • Run 1: Traditional Manufacturing, Push
  • Run 2: Traditional Manufacturing with 5S
  • Run 3: Pull & Improved Work Balance
  • Run 4: One Piece Flow, Further Balance
  • Run 5: Pull System based on TAKT
  • Run 4 & 5: The Hidden Factory

©

LEGO
Simulation
LEGO is a registered trademark of Interlego A.G.
Learning Objective
Enhance your
understanding of Lean
Manufacturing through a
hands-on simulation
Lean System Concepts

• 5 S - Sort, Store, Shine, Standardize, Sustain


• Waste Elimination – Transportation,
Inventory, Motion, Waiting, Over-processing,
Overproduction, Defects

• Make to Use - Pull System


• Visual Factory
The Toyota Production System
GOALS: Best Quality Lowest Cost Shortest Lead Time
KEY IS: Elimination of Waste
JUST-IN-TIME AUTONOMATION
(Jidoka)
• Continuous Flow • “Automation with a
• Pull System Human Touch”
• Takt Time • Machines Stop for
Abnormalities
• Separate Man &
Machine
• Error Proofing
(Poka Yoke)
Leveling Standardized Continuous Improvement
(Heijunka) Work (Kaizen)

Stability
(e.g.: Equipment Reliability; Stable Processes, Quality, Suppliers)

PEOPLE
Source: John Shook & TSSC
Run1: Traditional Manufacturing, Push
MULTIPLE PRODUCTION INSTRUCTIONS

A B

Final
Subassemblies Assemblies Shipping
Batch
Batch Flow Batch Flow Shipments
Run1: Traditional Manufacturing, Push

A B

LEAD TIME

Start Ship
Run 2: Traditional Manufacturing with 5S
ORGANIZED WORKPLACE

A B

Batch Flow Batch Flow Batch Shipments


Run 2: Traditional Manufacturing with 5S

A B

LEAD TIME

Start Ship
Workload Distribution

Work
Content
per
Unit
A B Ship A B Ship

RUN 1 RUN 2
• 5s Reduces A & B Work
Content
Run 3: Pull & Improved Work Balance
SINGLE
PRODUCTION
INSTRUCTION

A B

Store

Make-To-Use Batch Flow Batch Shipments


Run 3: Pull & Improved Work Balance

A B

Store
LEAD TIME

Start Ship
Workload Distribution

Work
Content
per
Unit
A B Ship A B Ship

RUN 2 RUN 3
• Work Balance of
Changeover
Run
: 4: One Piece Flow, Further Balance

A B

Store Store

Make to Use Make to Use Flexible Shipments


One Piece Flow One Piece Flow Excess Finished Goods
Run
: 4: One Piece Flow, Further Balance

A B

Store Store
LEAD TIME

Start Ship
Workload Distribution

Work
Content
per
Unit
A B Ship A B Ship

RUN 3 RUN 4
•Rapid Changeover
•Work Balance
Run 5: Pull system based on TAKT

A B

Store Store

Make to Use Make to Use Flexible Shipments


One Piece Flow One Piece Flow Relaxed Pace
Run 4 & 5: The Hidden Factory
RESULTS
• 50% + HIGHER THROUGHPUT VS. RUN 3
• SHORTENED LEAD TIME (time from closest
Store)
• VERY FLEXIBLE to Customer Demand Changes
HOW
• Very Rapid Changeovers
• Small Batches
• Improved Work Balance
• by Continually Eliminating Waste and Producing
to TAKT

LEGO LEGO Simulation Simulation © LEGO is a registered trademark of Interlego A.G.
Learning Objective Learning Objective Enhance your Enhance your understanding of Lean understanding of Lean Manufacturing
Lean System Concepts Lean System Concepts • 5 S - Sort, Store, Shine, Standardize, Sustain • Waste Elimination – Transportati
The Toyota Production System GOALS: GOALS: Best Quality Lowest Cost Shortest Lead Time KEY IS: KEY IS: Elimination
Run1: Traditional Manufacturing, Push Run1: Traditional Manufacturing, Push A B Subassemblies Final Assemblies Shipping Bat
Run1: Traditional Manufacturing, Push Run1: Traditional Manufacturing, Push A B LEAD TIME LEAD TIME Start Start Ship Ship
Run 2: Run 2: Traditional Manufacturing with 5S Traditional Manufacturing with 5S A B Batch Flow Batch Flow Batch Shipment
Run 2: Run 2: Traditional Manufacturing with 5S Traditional Manufacturing with 5S A B LEAD TIME LEAD TIME Start Start Ship
Workload Distribution Workload Distribution RUN 2 • 5s Reduces A & B Work Content Work Content per Unit A B Ship RUN 1 A
Pull & Improved Work Balance Pull & Improved Work Balance Run 3: Run 3: Run 3: A B Make-To-Use Batch Flow Batch Shipments S

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